JP6323820B2 - Solar cell module and manufacturing method thereof - Google Patents

Description

  The present invention relates to a solar cell module and a manufacturing method thereof.

  In patent document 1, it is proposed to use a white resin sheet as a resin sheet for constituting the filler layer of the solar cell module. By configuring the portion of the filler layer located on the back surface side of the solar cell with the white resin sheet, the light incident efficiency to the solar cell can be improved, so that the output characteristics of the solar cell module can be improved.

JP 2006-320992 A

  There is a desire to further improve the output characteristics of solar cell modules.

  The main object of the present invention is to improve the output characteristics of a solar cell module.

  In the method for manufacturing a solar cell module according to the present invention, at least one solar cell string including a plurality of solar cells connected by a wiring material is prepared, and a colored resin sheet is disposed on one side of the solar cell string and A laminated body is obtained by arranging a transparent resin sheet on the other side of the solar cell string, and the laminated body is heated while being heated to a temperature at which the storage elastic modulus of the transparent resin sheet is higher than the storage elastic modulus of the colored resin sheet. By being pressurized, it is located on one side of the solar cell string, is located on the other side of the solar cell string, and a colored filler layer composed of the colored resin sheet, from the transparent resin sheet A transparent battery layer comprising a transparent filler layer, wherein an interface between the colored filler layer and the transparent filler layer is Preparing a solar cell module which is located between the solar cells adjacent included in the solar cell string.

  The solar cell module according to the present invention includes a filler layer, and at least one solar cell string including a plurality of solar cells connected by a wiring member disposed in the filler layer, and the filler layer Includes a colored filler layer located on one side of the solar cell string and a transparent filler layer located on the other side of the solar cell string, the colored filler layer and the transparent filler And an interface between the colored filler layer and the transparent filler layer is located on the other side of the plurality of solar cells. And located on the other side of the center in the thickness direction of the plurality of solar cells.

  According to the present invention, the output characteristics of the solar cell module can be improved.

FIG. 1 is a schematic exploded cross-sectional view of a laminate in one embodiment of the present invention. FIG. 2 is a schematic cross-sectional view of a solar cell module according to an embodiment of the present invention. FIG. 3 is a schematic cross-sectional view of a solar cell module in a reference example.

  Hereinafter, an example of the preferable form which implemented this invention is demonstrated. However, the following embodiment is merely an example. The present invention is not limited to the following embodiments.

  In each drawing referred to in the embodiment and the like, members having substantially the same function are referred to by the same reference numerals. The drawings referred to in the embodiments and the like are schematically described, and the ratio of the dimensions of the objects drawn in the drawings may be different from the ratio of the dimensions of the actual objects. The dimensional ratio of the object may be different between the drawings. The specific dimensional ratio of the object should be determined in consideration of the following description.

  In the present embodiment, an example of a method for manufacturing the solar cell module 1 shown in FIG. 2 will be described with reference mainly to FIG.

  When manufacturing the solar cell module 1, first, the laminated body 20 shown in FIG. 1 is produced. Specifically, first, the solar cell 12 is prepared. One solar cell 12 may be prepared. Further, at least one solar cell string 15 including a plurality of solar cells 12 connected by the wiring member 14 may be prepared. Here, the example which prepares the solar cell string 15 containing the several solar cell 12 electrically connected by the wiring material 14 is demonstrated.

  Solar cell 12 has a light receiving surface 12a and a back surface 12b. The light receiving surface 12a is a main surface that mainly receives light among the two main surfaces of the solar cell 12, and the other main surface forms the back surface 12b. Generally, when electrodes are provided on both the light receiving surface 12a and the back surface 12b, the electrode provided on the back surface 12b has a larger area than the electrode provided on the light receiving surface 12a.

  Next, the laminated body 20 is produced by laminating | stacking the 1st protective member 10, the transparent resin sheet 16, the some solar cell 12, the colored resin sheet 17, and the 2nd protective member 11 in this order. In the stacked body 20, the colored resin sheet 17 is disposed on the back surface 12 b side of the plurality of solar cells 12. A transparent resin sheet 16 is disposed on the light receiving surface 12 a side of the plurality of solar cells 12.

  The first protection member 10 is a member that protects the light receiving surface 12 a side of the solar cell 12. The first protective member 10 has translucency. The first protective member 10 can be made of glass, for example.

  The second protection member 11 is a member that protects the back surface 12 b side of the solar cell 12. The second protective member 11 can be constituted by, for example, a resin sheet or a resin sheet including a reflective layer made of metal or the like.

  The transparent resin sheet 16 is disposed on the light receiving surface 12 a of the solar cell 12. Here, the “transparent resin sheet” is a resin sheet that substantially does not contain pigments and dyes and transmits incident light.

  The colored resin sheet 17 is disposed on the back surface 12 b of the solar cell 12. Here, the “colored resin sheet” is a resin sheet containing at least one of a pigment and a dye. The colored resin sheet 17 preferably contains a white pigment made of, for example, titanium oxide.

  The thicknesses of the transparent resin sheet 16 and the colored resin sheet 17 are not limited. The thickness of the transparent resin sheet 16 and the thickness of the colored resin sheet 17 may be the same or different. The thicknesses of the transparent resin sheet 16 and the colored resin sheet 17 can be about 300 μm to 600 μm, respectively.

  Next, the lamination process which laminates by pressing the laminated body 20 while heating is performed. In addition, the heating temperature of the laminated body 20 in a lamination process can be about 50 to 150 degreeC, for example. The pressure applied to the laminated body 20 in the laminating step can be, for example, about 50 kPa to 100 kPa.

  The solar cell module 1 shown in FIG. 2 can be completed by performing the laminate manufacturing process and the laminating process. The solar cell module 1 includes a solar cell 12. Specifically, the solar cell module 1 includes a solar cell string 15 including a plurality of solar cells 12 electrically connected by the wiring member 14.

  The plurality of solar cells 12 are disposed in a filler layer 13 disposed between the first protective member 10 and the second protective member 11. The filler layer 13 includes a colored filler layer 13a and a transparent filler layer 13b. The colored filler layer 13 a is disposed between the second protective member 11 and the back surface 12 b of the solar cell 12. The colored filler layer 13 a is composed of the colored resin sheet 17. For this reason, the colored filler layer 13a contains at least one of a pigment and a dye.

  The transparent filler layer 13 b is disposed between the light receiving surface 12 a of the solar cell 12 and the first protective member 10. The transparent filler layer 13 b is composed of a transparent resin sheet 16.

  On the second protective member 11, a terminal box to which a wiring material electrically connected to the plurality of solar cells 12 is electrically connected may be provided. A frame may be provided outside the solar cell module 1.

  By the way, generally, the resin sheet disposed on the light receiving surface side of the solar cell and the resin sheet disposed on the back surface side are made of the same resin material. For example, a resin sheet made of an ethylene / vinyl acetate copolymer containing a pigment such as titanium oxide is arranged on the back side of the solar cell, and an ethylene / vinyl acetate copolymer containing no pigment on the light receiving side of the solar cell. The resin sheet comprised by this is arranged. However, in this case, in the laminating step, a part of the colored resin sheet disposed on the back side may wrap around the light receiving surface of the solar cell. As a result, the colored filler layer 113a is positioned on the light receiving surface 112a of the solar cell 112 as in the solar cell module 100 shown in FIG. Therefore, the output characteristics of the solar cell module are deteriorated.

  On the other hand, in this embodiment, a resin sheet having a higher storage elastic modulus at the heating temperature of the laminate 20 in the laminating process than the colored resin sheet 17 is used as the transparent resin sheet 16. That is, the storage elastic modulus of the transparent resin sheet 16 is higher than the storage elastic modulus of the colored resin sheet 17 at the heating temperature of the laminate 20 in the laminating step. For this reason, the interface between the colored resin sheet 17 and the transparent resin sheet 16 is located on the back surface side of the light receiving surface 12 a of the solar cell 12 and on the light receiving surface 12 a side of the center in the thickness direction of the solar cell 12. Therefore, it is possible to effectively suppress a part of the colored resin sheet 17 from wrapping around the light receiving surface 12a of the solar cell 12 in the laminating step. Therefore, it becomes possible to manufacture the solar cell module 1 having improved output characteristics.

  By the way, from the viewpoint of suppressing the colored resin sheet from wrapping around the light receiving surface of the solar cell in the laminating step, the interface between the colored resin sheet and the transparent resin sheet is located on the back side from the center in the thickness direction of the solar cell. It is also conceivable to perform a laminating process as described above. However, in this case, the light reflected at the interface between the colored resin sheet and the transparent resin sheet is likely to enter the side surface of the solar cell. Therefore, the condensing efficiency to the light-receiving surface of a solar cell falls. On the other hand, in this embodiment, the interface between the colored resin sheet 17 and the transparent resin sheet 16 is located closer to the light receiving surface 12 a than the center in the thickness direction of the solar cell 12. For this reason, the condensing efficiency to the light-receiving surface 12a of the solar cell 12 can be improved. As a result, further improved output characteristics can be obtained.

  The method for making the storage elastic modulus at the heating temperature of the laminate 20 in the laminating step of the transparent resin sheet 16 higher than the storage elastic modulus at the heating temperature of the laminate 20 in the laminating step of the colored resin sheet 17 is not particularly limited. For example, a resin sheet containing a crosslinkable resin made of ethylene / vinyl acetate copolymer (EVA) or the like is used as the colored resin sheet 17, and a non-crosslinkable resin made of polyolefin such as polyethylene or polypropylene is used as the transparent resin sheet 16. You may use the resin sheet containing. In that case, the colored filler layer 13a contains a crosslinkable resin, and the transparent resin sheet 16 contains a non-crosslinkable resin. The crosslinkable resin may have a gel fraction of 50% or more. The non-crosslinkable resin may have a gel fraction of less than 50%. The “gel fraction” is measured by the following measuring method. 1 g of resin to be measured is prepared. The resin is immersed in 100 ml of xylene at 120 ° C. for 24 hours. Thereafter, the residue in xylene is taken out and dried at 80 ° C. for 16 hours. Then, the mass of the residue after drying is measured. From the obtained result, the gel fraction (%) is calculated based on the following formula (1).

  (Gel fraction (%)) = (Mass of residue (g)) / (Mass of resin before immersion (g)) (1)

From the viewpoint of obtaining a more improved solar cell module 1, the storage elastic modulus at the heating temperature of the laminate 20 in the laminating step of the transparent resin sheet 16 is stored at the heating temperature of the laminate 20 in the laminating step of the colored resin sheet 17. The elastic modulus is preferably 1.5 times or more, more preferably 3 times or more. However, if the storage elastic modulus at the heating temperature of the laminate 20 in the laminating step of the transparent resin sheet 16 is too high, the solar cell 12 may break. Therefore, the storage elastic modulus at the heating temperature of the laminate 20 in the laminating step of the transparent resin sheet 16 is preferably 1 × 10 ⁶ Pa or less.

Specifically, the storage modulus at a heating temperature of the laminate 20 in the lamination process of the colored resin sheet 17 is preferably 5 × is 10 5 ^Pa or less, more preferably at most 3 × 10 5 ^Pa, More preferably, it is 1 × 10 ⁵ Pa or less. The storage elastic modulus at the heating temperature of the laminate 20 in the laminating step of the transparent resin sheet 16 is preferably 8 × 10 ⁵ Pa to ⁵ × 10 ⁶ Pa.

  The storage elastic modulus of the transparent resin sheet 16 may be higher than the storage elastic modulus of the colored resin sheet 17 only at the heating temperature of the laminate 20 in the laminating step. The storage elastic modulus of the transparent resin sheet 16 may be higher than the storage elastic modulus of the colored resin sheet 17 not only at the heating temperature of the laminated body 20 in the laminating process but also at a temperature lower than the heating temperature of the laminated body 20. Good.

  The present invention includes various embodiments not described herein. For example, the solar cell may be a back junction type solar cell having first and second electrodes on the back surface side. The solar cell module may include one solar cell. As described above, the present invention includes various embodiments not described herein. Therefore, the technical scope of the present invention is defined only by the invention specifying matters according to the scope of claims reasonable from the above description.

DESCRIPTION OF SYMBOLS 1 ... Solar cell module 12 ... Solar cell 12a ... Light-receiving surface 12b ... Back surface 13 ... Filler layer 13a ... Colored filler layer 13b ... Transparent filler layer 16 ... -Transparent resin sheet 17 ... colored resin sheet 20 ... laminate

Claims (7)

Preparing at least one solar cell string including a plurality of solar cells connected by a wiring material;
By arranging a colored resin sheet on one side of the solar cell string and arranging a transparent resin sheet on the other side of the solar cell string, a laminate is obtained,
By pressing the laminate while heating to a temperature at which the storage elastic modulus of the transparent resin sheet is higher than the storage elastic modulus of the colored resin sheet, the transparent resin sheet is positioned on one side of the solar cell string and the colored A solar cell module comprising a colored filler layer composed of a resin sheet and a transparent filler layer located on the other side of the solar cell string and composed of the transparent resin sheet, wherein the colored filler The manufacturing method of a solar cell module which produces the solar cell module in which the interface of a material layer and the said transparent filler layer is located between the said adjacent solar cells contained in the said solar cell string. In the manufacturing method of the solar cell module according to claim 1,
A sheet containing a crosslinkable resin is used as the colored resin sheet, and a sheet containing a non-crosslinkable resin is used as the transparent resin sheet. In the manufacturing method of the solar cell module of Claim 2,
A sheet containing an ethylene / vinyl acetate copolymer is used as the colored resin sheet, and a sheet containing polyolefin is used as the transparent resin sheet. In the manufacturing method of the solar cell module as described in any one of Claims 1-3,
The stacked body is pressurized so that the colored filler layer is located on one side of the other main surface of the plurality of solar cells and on the other side of the center in the thickness direction of the plurality of solar cells. A filler layer;
At least one solar cell string including a plurality of solar cells connected by a wiring material disposed in the filler layer;
With
The filler layer includes a colored filler layer located on one side of the solar cell string and a transparent filler layer located on the other side of the solar cell string,
The interface between the colored filler layer and the transparent filler layer is located between adjacent solar cells included in the solar cell string,
The interface between the colored filler layer and the transparent filler layer is one side of the other main surface of the plurality of solar cells, and the other than the center in the thickness direction of the plurality of solar cells. Located on the side,
Solar cell module. In the solar cell module according to claim 5,
The colored filler layer contains a crosslinkable resin;
The transparent filler layer contains a non-crosslinkable resin. In the solar cell module according to claim 6,
The colored filler layer contains an ethylene / vinyl acetate copolymer,
The transparent filler layer contains a polyolefin.

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